Dryer Optimisation – Stempher C.V.
Stempher is an independent producer of polyethylene and paper packaging with more than one hundred years of experience and one of the most modern factories in Europe.
Operational were approached to optimise energy consumption at the Stempher factory.
Objectives:
- Optimise dryer control to reduce energy use and exhaust airflow.
- Improve process control of the drying systems for improved efficiency and product quality.
- Decrease the size and costs of the emission control system.
Actions:
Process Investigation:
Operational undertook a detailed on-site review of the process, design parameters and the actual operating conditions and existing press control systems.
Optimisation:
The plant was optimised using a combination of air recirculation, rebalancing of air-flows, advanced solvent level (LEL) monitoring and control resulting in lower exhaust volumes and higher solvent concentrations. Final exhaust volumes reduced from 36,000 m3/hr to 15,000 m3/hr.
Continuous Monitoring:
After continuous monitoring, Operational assisted Stempher C.V. with technical and commercial aspects of the selection of VOC abatement equipment. Operational also fully managed the project.
Outcomes:
Reduction in Capital Investment:
Regenerative Thermal Oxidisers (RTO): as a result of the plant being optimised, the lower air volumes reduced the size of the RTO required, resulting in significant savings in capital investment.
Reduction in Operating Costs:
Significant reduction in fan power consumption was achieved due to reduction in air volumes. Fuel costs were also reduced with better achievement of auto thermal conditions in the RTO due to increased solvent concentration sustaining combustion.
These energy savings reduced emissions of CO2 by 50%.